Gas dispersion manufacture of nanoparticulates, and nanoparticulate-containing products and processing thereof

Abstract

In one aspect, the present invention relates to a method of making multi-phase particles that include nanoparticulates and matrix, which maintains the nanoparticulates in a dispersed state. A flowing gas dispersion is generated that includes droplets of a precursor medium dispersed in a gas phase. The precursor medium contains liquid vehicle and at least a first precursor to a first material and a second precursor to a second material. The multi-phase particles are formed from the gas dispersion by removing at least a portion of the liquid vehicle from the droplets of precursor medium. The nanoparticulates in the multi-phase particles include the first material and the matrix in the multi-phase particles includes the second material.

1 .- 11 . (canceled)  
   
   
       12 . A gas dispersion method for making nanoparticulates, the method comprising: 
 generating a flowing gas dispersion, as generated the gas dispersion comprising droplets of a precursor medium dispersed in a gas phase, with the precursor medium comprising liquid vehicle and at least two precursors, a first said precursor being a precursor to a first material and a second said precursor being a precursor to a second material, the second material being a surface-modifying material;    in the gas dispersion, forming particles dispersed in the gas phase, the particles each comprising the second material and nanoparticulates that include the first material;    the forming particles comprising removing at least a portion of the liquid vehicle from the droplets;    wherein, the particles are decomposable in a liquid dispersion medium to release the nanoparticulates from the particles for dispersion of the nanoparticulates in the liquid dispersion medium; and    wherein, when the particles are decomposed in and the nanoparticulates are dispersed in the liquid dispersion medium, at least a portion of the second material modifies a surface of the dispersed nanoparticulates.    
   
   
       13 . The method of  claim 12 , wherein the second material comprises a dispersing agent to inhibit agglomeration of the nanoparticulates in the dispersion medium.  
   
   
       14 . The method of  claim 12 , wherein the second material comprises a surfactant interacting with the nanoparticulates to modify surface properties of the nanoparticulates when the particles are decomposed in the liquid dispersion medium.  
   
   
       15 . The method of  claim 12 , wherein the second material coats the surface of the nanoparticulates when the particles are decomposed in the liquid dispersion medium.  
   
   
       16 . The method of  claim 12 , wherein the second material is chemically reactable with to functionalize the surface of the nanoparticulates.  
   
   
       17 .- 18 . (canceled)  
   
   
       19 . The method of  claim 12 , wherein after the forming particles, the method comprises: 
 decomposing the particles in the liquid dispersion medium; and    in the liquid dispersion medium, releasing the nanoparticulates from the particles.    
   
   
       20 . The method of  claim 19 , wherein during or after the decomposing, the method comprises: 
 reacting the second material with the nanoparticulates to functionalize a surface of the nanoparticulates.    
   
   
       21 . The method of  claim 19 , wherein during the releasing, the second material interacts with the nanoparticulates to inhibit agglomeration and aid dispersion of the nanoparticulates in the liquid dispersion medium.  
   
   
       22 . The method of  claim 12 , wherein the particles comprise matrix that maintains the nanoparticulates in a dispersed state in the particles, the matrix comprising the second material.  
   
   
       23 .- 49 . (canceled)  
   
   
       50 . A gas dispersion method for making nanoparticulates, the method comprising: 
 generating a flowing gas dispersion, as generated the gas dispersion comprising droplets of a precursor medium dispersed in a gas phase, with the precursor medium comprising liquid vehicle and at least two precursors, a first said precursor being a precursor to a first material and a second said precursor being a precursor to a second material;    in the gas dispersion, forming multi-phase particles dispersed in the gas phase, the multi-phase particles each comprising a dispersion of nanoparticulates and matrix, the nanoparticulates maintained in a dispersed state by the matrix, the nanoparticulates comprising the first material and the matrix comprising the second material;    the forming multi-phase particles comprising removing at least a portion of the liquid vehicle from the droplets to the gas phase and reacting the first precursor to form the first material;    wherein, prior to the forming multi-phase particles, the gas dispersion comprises a reducing agent; and    wherein the forming multi-phase particles comprises reaction of the reducing agent to promote chemical reduction to form the first material.    
   
   
       51 . The method of  claim 50 , wherein during the generating, the reducing agent is contained within the precursor medium.  
   
   
       52 . The method of  claim 50 , wherein during the generating, the reducing agent is dissolved in the liquid vehicle of the precursor medium.  
   
   
       53 . The method of  claim 50 , wherein the reaction of the reducing agent reduces a temperature at which the first material forms in the gas dispersion.  
   
   
       54 . The method of  claim 50 , wherein reaction of the reducing agent reduces a temperature at which the first material forms in the gas dispersion by at least 50° C.  
   
   
       55 .- 92 . (canceled)  
   
   
       93 . A particulate product comprising: 
 multi-phase particles comprising a dispersion of nanoparticulates and matrix, with the nanoparticulates maintained in a dispersed state by the matrix, the matrix comprising a surface-modifying material; and    wherein the particles are decomposable to release the nanoparticulates from the dispersed state with at least a portion of the surface-modifying material remaining with the nanoparticulates and modifying a surface of the nanoparticulates.    
   
   
       94 . The particulate product of  claim 93 , wherein the surface-modifying material comprises a dispersing agent for inhibiting agglomeration of the nanoparticulates when released from the dispersed state.  
   
   
       95 . The particulate product of  claim 93 , wherein the surface-modifying material comprises a surfactant.  
   
   
       96 . The particulate product of  claim 93 , wherein the surface-modifying material comprises a polymer.  
   
   
       97 . The particulate product of  claim 93 , wherein the surface-modifying material is a first matrix material and the matrix comprises a second matrix material that is different than the surface-modifying material; and 
 the second matrix material is selectively removable from the multi-phase particles relative to the surface-modifying material.    
   
   
       98 . The particulate product of  claim 97 , wherein the surface-modifying material is a polymer and the second matrix material is an inorganic salt.  
   
   
       99 .- 124 . (canceled)